Diode package structure and manufacturing method thereof

ABSTRACT

A diode package structure includes a substrate, at least one diode chip and an opaque encapsulating layer. The substrate has an electrically conductive layer. At least one diode chip is mounted on the substrate and electrically connected to the electrically conductive layer. The opaque encapsulating layer has a cap portion and a sidewall portion, wherein the sidewall portion is connected to and surrounds the substrate to jointly form a concave structure, the cap portion is connected between a sidewall of the diode chip and the sidewall portion, wherein a first contact vertex of the cap portion and the sidewall of the diode chip is higher than a second contact vertex of the cap portion and the sidewall portion.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to Taiwan Application Serial Number 109144520, filed Dec. 16, 2020, which is herein incorporated by reference in its entirety.

BACKGROUND Field of Invention

The present disclosure relates to a diode package structure and manufacturing method thereof.

Description of Related Art

Light emitting diode is a light-emitting element made of semiconductor material that can convert electrical energy into light. It has the advantages of small size, high energy conversion efficiency, long life, power saving, etc., so it can be widely used as light source in various electronic applications.

The light emitting diode packaging structure includes various packaging colloids to meet different needs. Different types of packaging colloids often cause the interface between different colloids to easily peel off due to the different properties of the colloid materials. In view of this, suppliers need various solutions to control the situation of interface peeling.

SUMMARY

One aspect of the present disclosure is to provide a diode package structure, which includes a substrate, at least one diode chip and an opaque encapsulating layer. The substrate has an electrically conductive layer. At least one diode chip is mounted on the substrate and electrically connected to the electrically conductive layer. The opaque encapsulating layer has a cap portion and a sidewall portion, wherein the sidewall portion is connected to and surrounds the substrate to jointly form a concave structure, the cap portion is connected between a sidewall of the diode chip and the sidewall portion, wherein a first contact vertex of the cap portion and the sidewall of the diode chip is higher than a second contact vertex of the cap portion and the sidewall portion.

Another aspect of the present disclosure is to provide a diode package structure manufacturing method, which includes following steps of providing a substrate; mounting diode chips on the substrate; forming a first opaque encapsulating layer among the diode chips; forming a transparent encapsulating layer to cover the diode chips and the first opaque encapsulating layer; forming a trench to expose the substrate in an area where the transparent encapsulating layer and the first opaque encapsulating layer are overlapped; and filling a second opaque encapsulating layer in the trench, wherein a first contact vertex of the first opaque encapsulating layer and a sidewall of each diode chip is higher than a second contact vertex of the first opaque encapsulating layer and the second opaque encapsulating layer.

In one or more embodiments, an interface is formed between the transparent encapsulating layer and the second opaque encapsulating layer, an angle between the interface and a connection line between the first contact vertex and the second contact vertex is an acute angle.

In one or more embodiments, the diode package structure further includes a transparent encapsulating layer filled within the concave structure to cover the diode chip, and a first interface is formed between the sidewall portion and the transparent encapsulating layer, wherein an angle between the first interface and a connection line between the first contact vertex and the second contact vertex is an acute angle.

In one or more embodiments, a second interface formed between the transparent encapsulating layer and the cap portion includes a curved surface.

In one or more embodiments, the cap portion covers the electrically conductive layer.

In one or more embodiments, the opaque encapsulating layer includes black encapsulating glue.

In one or more embodiments, the opaque encapsulating layer includes white encapsulating glue.

In one or more embodiments, the diode chip is a light-emitting diode.

In one or more embodiments, the diode chip is a photodiode.

In one or more embodiments, the diode chip is a Zener diode.

In summary, the diode package structure and its manufacturing method disclosed herein can make the two interfaces joined by the transparent encapsulating layer and the opaque encapsulating layer form an acute angle, which is less prone to peeling during thermal expansion and contraction compared to a circular leading angle at the encapsulating layer interface of the conventional diode package structure.

It is to be understood that both the foregoing general description and the following detailed description are by examples, and are intended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be more fully understood by reading the following detailed description of the embodiment, with reference made to the accompanying drawings as follows:

FIG. 1 illustrates a cross sectional view of a diode package structure in accordance with an embodiment of the present disclosure; and

FIGS. 2-4 illustrate manufacturing steps of cross sectional views of a diode package structure in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION

It is to be noted that the following descriptions of preferred embodiments of this disclosure are presented herein for purpose of illustration and description only. It is not intended to be exhaustive or to be limited to the precise form disclosed. Also, it is also important to point out that there may be other features, elements, steps and parameters for implementing the embodiments of the present disclosure which are not specifically illustrated. Thus, the specification and the drawings are to be regard as an illustrative sense rather than a restrictive sense. Various modifications and similar arrangements may be provided by the persons skilled in the art within the spirit and scope of the present disclosure. In addition, the illustrations may not necessarily be drawn to scale, and the identical elements of the embodiments are designated with the same reference numerals.

Reference is made to FIG. 1, which illustrates a cross sectional view of a diode package structure in accordance with an embodiment of the present disclosure. The diode package structure 100 includes a substrate 102, at least one diode chip, and an encapsulating layer. In some embodiments of the present disclosure, the substrate 102 has an electrically conductive layer 102 a to conduct electric current required for operating the diode. In some embodiments of the present disclosure, the substrate 102 may be a flat plate, for example, a BT board, an EMC board, an SMC board, a ceramic board, a PCB board, or a Sapphire board. In some embodiments of the present disclosure, the electrically conductive layer 102 a may be a metal plated layer, but is not limited thereto.

In some embodiments of the present disclosure, the diode chip 106 a may be a light-emitting diode, and the diode chip 106 b may be a Zener diode or a photodiode. In some embodiments of the present disclosure, the diode chip 106 a may be a light-emitting diode, and the diode chip 106 b may also be a light-emitting diode (for example, a light-emitting diode of a different color). In some embodiments of the present disclosure, the diode chips (106 a, 106 b) can both be Zener diodes or photodiodes. The diode chip (106 a, 106 b) is die-bonded on the substrate 102 and is electrically connected to the electrically conductive layer 102 a on the substrate 102 (for example, achieved by wire bonding or welding). In some embodiments of the present disclosure, the diode chip may be a traditional face-up chip, a vertical chip or a flip chip.

In some embodiments of the present disclosure, the encapsulating layer may include a transparent encapsulating layer 108 and an opaque encapsulating layer 104. The opaque encapsulating layer 104 has a cap portion 104 a and a sidewall portion 104 b, and the sidewall portion 104 b is connected to and surrounds the substrate 102 to form a concave structure 108 a. The cap portion 102 a is connected between adjacent diode chips (106 a, 106 b), and between the sidewall of the diode chip (106 a or 106 b) and the sidewall portion 104 b, so as to shield or cover the upper surface of the substrate 102 or the electrically conductive layer 102 a. Therefore, the components and the electrically conductive layer will not have color shift or brightness degradation due to oxidation and discoloration, which can increase the product life. In some embodiments of the present disclosure, the cap portion 104 a and the sidewall portion 104 b may be the same encapsulating layer, so as to avoid interface peeling problems or other shortcomings caused by different materials. In some embodiments of the present disclosure, the opaque encapsulating layer 104 can be a white encapsulating layer or a black encapsulating layer, so as to meet different application environments. For example, the white encapsulating layer can increase the light reflectivity to enhance the light efficiency by about 3% to 40%, and the black encapsulating layer can reduce the noise ratio of optical components. In some embodiments of the present disclosure, the transparent encapsulating layer 108 is filled into the concave structure 108 a formed by the sidewall portion 104 b and the substrate 102 to cover the diode chips (106 a, 106 b), and forms a second interface 107 c with the cap portion 104 a. In some embodiments of the present disclosure, the transparent encapsulating layer 108 may be organic glue, inorganic glue, or a mixture thereof in any ratio, such as silicon, epoxy, fluorine, etc. In some embodiments of the present disclosure, the opaque encapsulating layer 104 may be an organic glue or an inorganic glue, and may include ceramic, metal, glass, titanium dioxide, or silicon dioxide.

In some embodiments of the present disclosure, a first contact vertex 109 a (i.e., an interface peak) of the cap portion 104 a and a sidewall of the diode chip 106 a is higher than a second contact vertex 109 b (i.e., an interface peak) of the cap portion 104 a and the sidewall portion 104 b. In some embodiments of the present disclosure, a first interface 107 b is formed between the transparent encapsulating layer 108 and the sidewall portion 104 b, wherein an angle θ between the first interface 107 b and a connection line 107 a between the first contact vertex 109 a and the second contact vertex 109 b is an acute angle such that the interface (i.e., 107 b and 107 c) between the transparent encapsulating layer 108 and the opaque encapsulating layer 104 is less likely to cause peeling problems.

In some embodiments of the present disclosure, a second interface 107 c formed between the transparent encapsulating layer 108 and the cap portion 104 a includes a curved surface.

Reference is made to FIGS. 2-4, which illustrate manufacturing steps of cross sectional views of a diode package structure in accordance with embodiments of the present disclosure.

In FIG. 2, a substrate 202 is provided, and a plurality of diode chips 206 are die-bonded on the substrate 202, and each diode chip 206 is electrically connected to the substrate 202. Next, a first opaque encapsulating layer 204 a is formed between adjacent diode chips 206, thereby forming a cap portion similar to that in FIG. 1. In some embodiments of the present disclosure, the diode chip 206 may be at least one of a light-emitting diode, a photodiode, and a Zener diode. In some embodiments of the present disclosure, the substrate 202 may be a flat plate, such as a BT board, an EMC board, an SMC board, a ceramic board, a PCB board, or a Sapphire board. In some embodiments of the present disclosure, the diode chip 206 may be a traditional face-up chip, a vertical chip or a flip chip.

In FIG. 3, a transparent encapsulating layer 208 is formed to cover the diode chips 206 and the first opaque encapsulating layer 204 a. An interface 207 c is formed between the transparent encapsulating layer 208 and the first opaque encapsulating layer 204 a. Then, a trench 205 is formed in an area where the transparent encapsulating layer 208 and the first opaque encapsulating layer 204 a are overlapped or laminated to expose the substrate 202. In some embodiments of the present disclosure, a portion of trench 205 includes a groove 202 a on a surface of the substrate 202.

In FIG. 4, the trench 205 is filled with a second opaque encapsulating layer 204 b to form the aforementioned sidewall portion 104 b. A first contact vertex 209 a (i.e., an interface peak) of the first opaque encapsulating layer 204 a and the sidewall of the diode chip 206 is higher than a second contact vertex 209 b (i.e., an interface peak) of the first opaque encapsulating layer 204 a and the second opaque encapsulating layer 204 b. Then, diode package structure monomers 200 can be separated by cutting along a cutting line 210. In some embodiments of the present disclosure, each diode package structure monomer 200 may also include two or more diode chips 206, for example, the diode package structure includes a light-emitting diode, a photodiode, or a Zener diode, or multiple light-emitting diodes, multiple photodiodes or multiple Zener diodes.

In some embodiments of the present disclosure, an interface 207 b is formed between the transparent encapsulating layer 208 and the second opaque encapsulating layer 204 b, and an angle θ between the interface 207 b and a connection line 207 a between the first contact vertex 209 a and the second contact vertex 209 b is an acute angle, which makes the interfaces (i.e., interfaces 207 b and 207 c) between the transparent encapsulating layer 208, the first opaque encapsulating layer 204 a and the second opaque encapsulating layer 204 b less likely to cause peeling problems.

In some embodiments of the present disclosure, the first opaque encapsulating layer 204 a and the second opaque encapsulating layer 204 b may be the same encapsulating layer, so as to avoid interface peeling problems or other shortcomings caused by different materials. In some embodiments of the present disclosure, the first opaque encapsulating layer 204 a and the second opaque encapsulating layer 204 b may be white or black encapsulating layers, so as to meet different application environments. For example, a white encapsulating layer can increase light reflectivity to enhance light efficiency by about 3% to 40%, and a black encapsulating layer can reduce the noise ratio of optical components. In some embodiments of the present disclosure, the transparent encapsulating layer 208 can be organic glue, inorganic glue or a mixture thereof in any ratio, such as silicon, epoxy, fluorine, etc. In some embodiments of the present disclosure, the first and second opaque encapsulating layers (204 a, 204 b) can be organic glue or inorganic glue, and can include ceramics, metals, glass, titanium dioxide, or silicon dioxide.

In summary, the diode package structure and its manufacturing method disclosed herein can make the two interfaces joined by the transparent encapsulating layer and the opaque encapsulating layer form an acute angle, which is less prone to peeling during thermal expansion and contraction compared to a circular leading angle at the encapsulating layer interface of the conventional diode package structure.

Although the present invention has been described in considerable detail with reference to certain embodiments thereof, other embodiments are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the embodiments contained herein.

It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims. 

What is claimed is:
 1. A diode package structure comprising: a substrate having an electrically conductive layer; at least one diode chip disposed on the substrate and electrically connected to the electrically conductive layer; and an opaque encapsulating layer having a cap portion and a sidewall portion, wherein the sidewall portion is connected to and surrounds the substrate to jointly form a concave structure, the cap portion is connected between a sidewall of the diode chip and the sidewall portion, wherein a first contact vertex of the cap portion and the sidewall of the diode chip is higher than a second contact vertex of the cap portion and the sidewall portion.
 2. The diode package structure of claim 1 further comprising a transparent encapsulating layer filled within the concave structure to cover the diode chip, and a first interface is formed between the sidewall portion and the transparent encapsulating layer, wherein an angle between the first interface and a connection line between the first contact vertex and the second contact vertex is an acute angle.
 3. The diode package structure of claim 2, wherein a second interface formed between the transparent encapsulating layer and the cap portion comprises a curved surface.
 4. The diode package structure of claim 1, wherein the cap portion covers the electrically conductive layer.
 5. The diode package structure of claim 1, wherein the opaque encapsulating layer comprises white encapsulating glue.
 6. The diode package structure of claim 1, wherein the opaque encapsulating layer comprises black encapsulating glue.
 7. The diode package structure of claim 1, wherein the diode chip comprises a light-emitting diode.
 8. The diode package structure of claim 1, wherein the diode chip comprises a photodiode.
 9. The diode package structure of claim 1, wherein the diode chip comprises a Zener diode.
 10. A diode package structure manufacturing method comprising: providing a substrate; mounting diode chips on the substrate; forming a first opaque encapsulating layer among the diode chips; forming a transparent encapsulating layer to cover the diode chips and the first opaque encapsulating layer; forming a trench to expose the substrate in an area where the transparent encapsulating layer and the first opaque encapsulating layer are overlapped; and filling a second opaque encapsulating layer in the trench, wherein a first contact vertex of the first opaque encapsulating layer and a sidewall of each diode chip is higher than a second contact vertex of the first opaque encapsulating layer and the second opaque encapsulating layer.
 11. The method of claim 10, wherein an interface is formed between the transparent encapsulating layer and the second opaque encapsulating layer, an angle between the interface and a connection line between the first contact vertex and the second contact vertex is an acute angle.
 12. The method of claim 10, wherein the first and second opaque encapsulating layers comprise white encapsulating glue.
 13. The method of claim 10, wherein the first and second opaque encapsulating layers comprise black encapsulating glue.
 14. The method of claim 10, wherein the diode chips comprise light-emitting diodes.
 15. The method of claim 10, wherein the diode chips comprise photodiodes.
 16. The method of claim 10, wherein the diode chips comprise Zener diodes. 